Audi A4 Avant 95-01 Service & Repair Manual

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20-1
Fuel supply system, servicing
guidelines
Safety precautions
WARNING!
When removing and installing fuel pump or
fuel gauge sensor from a partially filled fuel
tank:
BEFORE beginning work, place exhaust
extraction system suction pipe near fuel tank
opening so escaping fuel vapors can be
immediately sucked off.
If no exhaust extraction system is available,
use a radial fan (with motor located outside
airflow) with volume of at least 9 cfm.
Wear fuel-resistant gloves whenever working
with open parts of the fuel system.
Be sure the ignition is switched off when:
Disconnecting fuel injection system wiring.
Connecting or disconnecting test equipment
leads.
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BEFORE cranking the engine at starting RPM
(such as compression testing) disable the
fuel injection and ignition systems:
Disconnect the ignition coil power output
stage.
Disconnect harness connectors from all fuel
injectors.
After the work is completed, erase
Diagnostic Trouble Code (DTC) memory.
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20-2
WARNING!
Fire hazard! Do NOT have anything in the
area that can ignite gasoline!
Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.
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20-3
CAUTION!
BEFORE disconnecting the battery:
Stop the engine.
Be sure the ignition is switched off (also
applies when connecting the battery). Failure
to do so may damage the Engine Control
Module (ECM).
Be sure of the proper radio code (for vehicles
equipped with coded anti-theft radio)
Be sure the battery negative (-) cable is
disconnected, when:
Working on the electrical system.
Resistance (spot) welding or electric arc-
welding anywhere on the vehicle.
When connecting and disconnecting
electrical test equipment (LED voltage tester,
multimeter, etc.)
Be sure the ignition is switched off.
Use correct adapters from VW 1594
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connector test kit.
Always refer to the latest parts catalog to
ensure that you use original equipment fuel
hose clamps.
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20-4
Rules of cleanliness
CAUTION!
Whenever working on the fuel supply and fuel
injection systems, carefully observe the
following five rules of cleanliness:
1.- Thoroughly clean fuel system lines and hose
connections and surrounding area before
disconnecting.
2.- Place removed components on a clean
surface and cover them. Use plastic sheeting or
paper. Do not use fluffy rags that could leave
lint.
3.- Carefully cover or seal any components that
have been opened if repairs are not carried out
immediately.
4.- Install only clean parts. Do not remove
replacement parts from the packaging until
immediately before they are installed.
Do not use parts that have been stored without
packaging (from toolboxes, for example).
5.- When fuel system is opened avoid working
with compressed air whenever possible. Avoid
moving the vehicle if possible
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20-5
Observe following points before working on the
fuel supply system
CAUTION!
Obtain the radio Anti-theft code from the
customer before disconnecting the Battery
Ground strap.
With ignition switched OFF, disconnect Battery
Ground strap.
Open the fuel filler cap briefly and close
again.
Observe the following precautions when
removing or installing components from a filled or
partially filled fuel tank.
WARNING!
Empty the fuel tank before removal! If it is not
empty, the weight and sloshing fuel could
lead to injury, component damage or possible
fuel spillage.
Fuel tank must not be filled more than
1
/
3
maximum.
Reduce fuel quantity using fuel cart, if
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necessary.
Do NOT allow fuel to contact skin! Wear fuel-
resistant gloves!
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20-6
Fuel supply system, servicing
(vehicles with front wheel drive
and 1.8 ltr. turbo or 2.8 ltr.
engine)
Note:
CAUTION!
Always refer to the latest parts catalog to
ensure that you use original equipment fuel
hose clamps.
VAG1921 spring clamp pliers are recommended
for installation
Always replace seals, O-rings and gaskets
during installation work.
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20-7
Fuel tank assembly, component overview
Note:
Always refer to the Parts Catalog for availability of
individual items in an assembly.
Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Return line
From engine
- Mark before removing
- Note direction of arrow on connecting
flange
2 -
20 Nm
3 -
Fuel filter
Location: Arrow points in flow direction.
4 -
Holding clamp
For fuel filter
5 -
Supply line
To the fuel filter
- Mark before removal
- Note direction of arrow on connecting
flange
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20-8
6 -
Mounting screw
25 Nm
To connect fuel-filler neck and Ground
(item 13 Page 20-8 )
7 -
Washer
8 -
Overflow hose
9 -
Rubber cap
10 -
Locking ring
11 -
Sealing ring
- Replace if damaged.
12 -
Cover
13 -
Ground connection
Location Fig. 1 , Page 20-10
- Connect wiring terminal with mounting
screw (item 6 ) Page 20-8 .
- After installing, check continuity between
metal ring on fuel filler neck and bare
chassis Ground point. spec: approx. 0
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20-9
14 -
Bleed line
To EVAP canister
15 -
Fuel tank
Removing and installing Page 20-19
16 -
25 Nm
- Note tightening sequence Page 20-23
17 -
Bracket
For clamp bands
18 -
Clamp bands
Removing and installing Page 20-19
- Note different lengths
- Note installation direction
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20-10
Fig. 1 Ground connection installation position
- Route Ground connection -arrow-, as shown in illustration.
- Ensure tight fit of electrical Ground connection to fuel filler neck Ground
clamp.
CAUTION!
After installation, check for continuity between Ground clamp on
filler neck and chassis Ground.
- Attach wiring terminal -1- with screw -2- for fuel filler neck.
Specification: approximately 0 .
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20-11
Fuel filler neck, component overview
(vehicles without ORVR)
Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Ground connection
Location Fig. 1 , Page 20-10
- Ensure tight fit of connector on filler neck
ring
- Connect wiring terminal with mounting
screw for plastic fuel filler neck (item 6
Page 20-8 )
- After installing, check continuity between
metal ring on fuel filler neck and chassis
Ground. Specified: approx. 0
2 -
Bleed line
To EVAP canister
3 -
Gravity valve
To remove valve, unclip upward out of the
filler neck
- Check valve for flow:
Valve vertical: open,
Valve tipped 45 : closed
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20-12
4 -
O-ring
-Replace
5 -
O-rings
-Replace
6 -
Bleed valve
Removing, installing, checking Fig. 1 ,
Page 20-13
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20-13
Fig. 1 Bleed valve removing, installing, checking
- To remove, unclip valve from side of filler neck.
Lever in rest position: Valve closed
Lever pressed in direction of arrow: Valve open
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20-14
Fuel filler neck, component overview
(vehicles with ORVR)
Vehicles with front wheel drive and 1.8 ltr. turbo
or 2.8 ltr. engine
1 -
Bleed line
To top of filler neck on fuel tank
2 -
Expansion tank
Clipped to fuel-filler neck
3 -
Tank ventilation valve
Clipped to fuel-filler neck
Ventilates fuel tank for pressure
compensation
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20-15
4 -
Ground connection
Location Fig. 1 , Page 20-10
- Ensure tight fit of connector on filler neck
ring
- Connect wiring terminal with mounting
screw for plastic fuel filler neck (item 6
Page 20-8 ).
- After installing, check continuity between
ring on fuel filler neck and chassis
Ground, spec: approx. 0
5 -
Gravity valve
To remove valve, unclip upward out of filler
neck
- Check valve for flow:
Valve vertical: Flow
Valve tipped 45 : No Flow
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20-16
6 -
O-ring
-Replace
7 -
Sealing ring
Installation position: Sealing lip points to
the fuel filler neck
8 -
O-rings
Different sizes
-Replace
9 -
Bleed valve
Removing, installing, checking Fig. 1 ,
Page 20-17
10 -
Bleed line
To EVAP canister
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20-17
Requirement
Tab -2- pressed in direction of arrow:
Tab -2- in OFF position:
Fig. 1 Bleed valve, removing, installing, checking
Fuel tank removed
- To remove, unclip valve from side of filler neck.
- Plug port -3- by hand.
- Blow into port -1-
Must be flow
Must NOT be flow.
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